[Vwdiesel] Pump timing/Reading a dial indicator

[Tim Hicks]

  I changed the timing belt on my Volvo/ VW 2.4L diesel and have been trying to set the injection timing. I must be doing something wrong because it will not run.
   
  I do know the "basic timing" is correct, that is the crankshaft and the camshaft are in the correct position according to my manuals. That’s fairly simple, so it must be the injection timing. I drove this car into my garage so it did run prior.
   
  I did notice that when I was placing the cam locking plate to lock the cam I had to turn it clockwise about an inch, inch and a quarter in order to lock the cam in the correct position. I thought to my self the timing must be off.
   
  I have followed my Volvo Factory manual step by step a hundred times and it still doesn’t run. The only thing I can think of is I am not reading the dial indicator correctly. By looking at the gauge is seems to be a no brainer.
   
  The gauge is a factory gauge so it is the correct one. It reads both metric and standard. The black marks and numbers are metric and those are the ones I have been using. It has a 5mm measuring range. The space between the marks equals 0.01mm
   
  The marks go from zero clockwise one full rotation would be 0.50
  0.05,  0.10, 0.15, 0.20, 0.25, 0.30, 0.35, 0.40, 0.45, 0.50
   
  To go beyond 0.50 you keep counting on the second rotation.
   
  0.05=0.55, 0.10=0.60, 0.15=0.65, 0.20=0.70, 0.25=0.75, 0.30=0.80. 0.80 is where I need to be. I can tell I’m on the second rotation by the smaller gauge which goes from 
  1mm to 5mm. I have to set it on a 2mm preload when I am on the second rotation the needle will read between the 2 and the 3.
   
  Is this correct? I have never used one before. Can anyone think of what I might be doing wrong? I hate to have it towed to the dealer. I have worked on cars since I was a teenager and have always been successful in my repairs; it kills me to have it towed to a repair shop.
   
  Tim Hicks